Method of making pile fabric and pile fabric made thereby



Dec. 25, 1962 N. COREY ETAL METHOD OF MAKING PILE FABRIC AND PILE FABRIC MADE THEREBY 2 Sheets-Sheet 1 Filed Sept. 14, 1959 INVENTORS Mcuoms Covey BY Cmapcas AND/pews ,4 TTOp/VE Dec. 25, 1962 N. COREY ET AL 3,070,134

METHOD OF MAKING PILE FABRIC AND PILE FABRIC MADE THEREBY Filed Sept. 14, 1959 2 Sheets-Sheet 2 TL 7 S o 3 INVENTORS MCI/01.48 c0196) CHAQLe's H. Anopaws alble means as shown in FIG. 8. A third weft 17 is inserted in the shed which is heat over the upstanding portion 2 of the noseboard 1 as shown in FIG. 9. The relaxing of the tension of the pile yarn permits a portion of the yarn to be forced over the noseboard with the third weft 17 'to form a second loop M (FIG. 9). The second loop M is held between the second weft 16 and third weft 17. It will be observed that there is no weft beneath the loop M so that a saving in material is accomplished and production is increased.

The cycle is then repeated to form the pile fabric shown in FIGS. 1 through 3.

It will be noted from FIG. 2 that the loops M are slightly shorter than the loops L. However, loop M does not have a weft therein but is held in place by the sec- 0nd weft 16 and third weft 17 which squeeze the lower portions of the loop M together to hold it securely in place. Hence, it will be seen that since the loops M do not have any weft there beneath, a lesser amount of weft thread is used without sacrificing the appearance of durability of the finished fabric.

The loops L are held in place by the coaction of wefts 17 and 16 from the outside and the weft which is within loop L.

As shown in FIG. 3, binder warp 12 goes over the wefts 17 and 16 and under weft 15 while the other binder warp 11 goes over weft 15 and under wefts 16 and 17. The stuffer yarn 13 goes under wefts 15 and 17 and over weft 16 in the usual manner.

In order to vary the height of the loops M, the noseboard 1 may be provided with a removable bar 20, as shown in FIG. 10. With this bar so in place, the loop M is of a lesser height. However, if this bar is removed, as shown in FIG. 11, the loop M will be of greater height since more pile yarn will be forced on upstanding portion 2 of the nose-board 1 by the reeds.

Another manner in which the height of the loops M may be varied is by regulating the tension on the pile yarn. The more tension on the pile yarn, the less height the loop M will have because less yarn is forced over the nose-board 1. However, less tension on the pile yarn will increase the size of loop M since more yarn will be forced over the nose-board 1.

It will be seen that the present invention provides an improved method of forming an improved pile fabric without the necessity of using pile wires or combs and which will utilize a lesser amount of yarn for the wefts gvilghout affecting the appearance or durability of the pile a ric.

As various changes may be made in the form, construction and arrangement of the parts herein without departing from the spirit and scope of the invention and without sacrificing any of its advantages, it is to be understood that all matter herein is to be interpreted as illustrative and not in a limiting sense.

Having thus described our invention, We claim:

1. The method of forming a pile fabric which comprises lowering the pile yarn and a first binder warp, raising a second binder warp, inserting a Weft of a first group of wefts in the shed, raising the pile yarn and said first binder warp, lowering said second binder warp, inserting a first weft of a second group of wefts in the shed, beating said first weft of said second set for a predetermined distance, lowering said first binder warp and said pile yarn, raising said second binder warp, inserting a second weft of said second group in said shed, beating said second weft for a greater distance than said first weft thereby moving the first weft forward to form a first loop between the Weft of the first group and the second weft of the second group, inserting a third weft of the second group in said shed, beating said third weft to form a second loop between said second and third wefts.

2. The method of forming a pile fabric which comprises lowering the pile yarn and a first binder warp, raising a second binder warp, inserting a weft of a first group of wefts in the shed, raising the pile yarn and said first binder warp, lowering said second binder warp, inserting a first weft of a second group of wefts in the shed, beating said first weft of said second group for a predetermined distance, lowering said first binder warp and said pile yarn, raising said second binder warp, inserting a second weft of said second group in said shed, beating said second weft for a greater distance than said first weft thereby moving the first weft forward to form a first loop between the weft of the first group and the second weft of the second group, slackening the tension on said pile yarn, inserting a third weft of the second group in said shed, and beating said third weft to form a second loop between said second and third wefts.

3. The method of forming a pile fabric which comprises lowering the pile yarn, a first binder warp and a stuffer yarn, raising a second binder warp, inserting a weft of a first group of wefts in the shed, raising the pile yarn and the first binder warp, lowering the second binder yarn, inserting a first weft of a second group of wefts in the shed, beating said fizst weft of said second group for a predetermined distance, lowering said first binder warp and said pile yarn, raising said second binder warp and said stuffer yarn, inserting a second weft of said second group in said shed, beating said second weft for a greater distance than said first Weft thereby moving the first weft forward to form a first loop between the weft of the first group and the second weft of the second group, lowering said stuifer yarn, slackening the tension on said pile yarn, inserting a third weft of the second group in said shed, and beating said th'rd weft to form a second loop between said second and third wefts.

4. A pile fabric comprising a pile yarn, first binder warps and second binder warps, said pile yarn forming first and second sets of pile loops, the first set of pile loops being held in place by spaced wefts, said second set of pile loops being held in place by adjacent wefts, a weft below said first set of pile loops and interposed between the spaced wefts holding said first set of pile loops in place, said first binder warps underlying the adjacent wefts which hold the second pile loops in place and overlying the weft below the first set of pile loops and the second binder warps overlying the adjacent wefts which hold the second set of pile loops in place and underlying the weft below the first set of pile loops.

5. A pile fabric as claimed in claim 4, wherein stuifer yarn is provided, said stuifer yarn underlying the weft below the first set of pile loops and one of the adjacent wefts which hold the second set of pile loops in place and overlying the other of said adjacent wefts which hold the second set of pile loops in place.

References Cited in the file of this patent UNITED STATES PATENTS 350,372 Leake Oct. 5, 1886 376,664 Leake Jan. 17, 1888 1,949,579 Parker Mar. 6, 1934 2,650,621 Crawford Sept. 1, 1953 2,714,399 Hoeselbarth Aug. 2, 1955 2,905,203 Hoeselbarth Sept. 22, 1956 2,981,292 Hoeselbarth Apr. 25, 1961 2,988,113 Smily June 13, 1961 

